Revision to Spec 03 30 00.pdf

P691 Aircraft Development and Maintenance Facility-Ph 2 eProject No. 1737036 Naval Air Station Patuxent River, MD

SECTION 03 30 00

CAST-IN-PLACE CONCRETE

THIS SECTION HAS BEEN DEVELOPED IN RESPONSE TO PPI-418

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN CONCRETE INSTITUTE (ACI)

ACI 117 (2010; Errata 2011) Specifications for Tolerances for Concrete Construction and Materials and Commentary

ACI 121R (2008) Guide for Concrete Construction Quality Systems in Conformance with ISO

ACI 301 (2016) Specifications for Structural Concrete

ACI 302.1R (2015) Guide for Concrete Floor and Slab Construction

ACI 304.2R (2017) Guide to Placing Concrete by Pumping Methods

ACI 304R (2000; R 2009) Guide for Measuring, Mixing, Transporting, and Placing Concrete

ACI 305R (2020) Guide to Hot Weather Concreting

ACI 306R (2016) Guide to Cold Weather Concreting

ACI 308.1 (2011) Specification for Curing Concrete

ACI SP-2 (2007; Abstract: 10th Edition) ACI Manual of Concrete Inspection

ACI SP-15 (2011) Field Reference Manual: Standard Specifications for Structural Concrete ACI 301-05 with Selected ACI References

AMERICAN HARDBOARD ASSOCIATION (AHA)

AHA A135.4 (1995; R 2004) Basic Hardboard

ASTM INTERNATIONAL (ASTM)

ASTM A53/A53M (2020) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, SECTION 03 30 00 Page 1

CUI

Welded and Seamless

ASTM A184/A184M (2019) Standard Specification for Welded Deformed Steel Bar Mats for Concrete Reinforcement

ASTM A615/A615M (2020) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A884/A884M (2019) Standard Specification for Epoxy-Coated Steel Wire and Welded Wire Reinforcement

ASTM A934/A934M (2016) Standard Specification for Epoxy-Coated Prefabricated Steel Reinforcing Bars

ASTM A1064/A1064M (2017) Standard Specification for Carbon-Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete

ASTM C31/C31M (2021a) Standard Practice for Making and Curing Concrete Test Specimens in the Field

ASTM C33/C33M (2018) Standard Specification for Concrete Aggregates

ASTM C39/C39M (2021) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C42/C42M (2020) Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete

ASTM C78/C78M (2021) Standard Test Method for Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading)

ASTM C94/C94M (2021b) Standard Specification for Ready-Mixed Concrete

ASTM C136/C136M (2019) Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

ASTM C138/C138M (2017a) Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete

ASTM C143/C143M (2020) Standard Test Method for Slump of Hydraulic-Cement Concrete

ASTM C150/C150M (2021) Standard Specification for Portland Cement

ASTM C172/C172M (2017) Standard Practice for Sampling Freshly Mixed Concrete

SECTION 03 30 00 Page 2

ASTM C173/C173M (2016) Standard Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method

ASTM C231/C231M (2017a) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

ASTM C260/C260M (2010a; R 2016) Standard Specification for Air-Entraining Admixtures for Concrete

ASTM C311/C311M (2022) Standard Test Methods for Sampling and Testing Fly Ash or Natural Pozzolans for Use in Portland-Cement Concrete

ASTM C330/C330M (2017a) Standard Specification for Lightweight Aggregates for Structural Concrete

ASTM C494/C494M (2019) Standard Specification for Chemical Admixtures for Concrete

ASTM C567/C567M (2019) Determining Density of Structural Lightweight Concrete

ASTM C595/C595M (2021) Standard Specification for Blended Hydraulic Cements

ASTM C618 (2019) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C803/C803M (2018) Standard Test Method for Penetration Resistance of Hardened Concrete

ASTM C873/C873M (2015) Standard Test Method for Compressive Strength of Concrete Cylinders Cast in Place in Cylindrical Molds

ASTM C900 (2015) Standard Test Method for Pullout Strength of Hardened Concrete

ASTM C920 (2018) Standard Specification for Elastomeric Joint Sealants

ASTM C1017/C1017M (2013; E 2015) Standard Specification for Chemical Admixtures for Use in Producing Flowing Concrete

ASTM C1074 (2019) Standard Practice for Estimating Concrete Strength by the Maturity Method

ASTM C1077 (2017) Standard Practice for Agencies Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Testing Agency Evaluation

ASTM C1107/C1107M (2020) Standard Specification for Packaged

SECTION 03 30 00 Page 3

Dry, Hydraulic-Cement Grout (Nonshrink)

ASTM C1260 (2021) Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)

ASTM C1293 (2008; R 2015) Standard Test Method for Determination of Length Change of Concrete Due to Alkali-Silica Reaction

ASTM C1567 (2021) Standard Test Method for Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method)

ASTM C1602/C1602M (2018) Standard Specification for Mixing Water Used in Production of Hydraulic Cement Concrete

ASTM C1778 (2016) Standard Guide for Reducing the Risk of Deleterious Alkali-Aggregate Reaction in Concrete

ASTM D1751 (2018) Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)

ASTM D1752 (2018) Standard Specification for Preformed Sponge Rubber, Cork and Recycled PVC Expansion Joint Fillers for Concrete Paving and Structural Construction

ASTM D2628 (1991; R 2016) Standard Specification for Preformed Polychloroprene Elastomeric Joint Seals for Concrete Pavements

ASTM D3042 (2017) Standard Test Method for Insoluble Residue in Carbonate Aggregates

ASTM D5759 (2012; R 2020) Characterization of Coal Fly Ash and Clean Coal Combustion Fly Ash for Potential Uses

ASTM D6690 (2015) Standard Specification for Joint and Crack Sealants, Hot Applied, for Concrete and Asphalt Pavements

ASTM E96/E96M (2021) Standard Test Methods for Gravimetric Determination ofWater Vapor Transmission Rate of Materials

ASTM E329 (2021) Standard Specification for Agencies Engaged in Construction Inspection, Testing, or Special Inspection

ASTM E1155 (2020) Standard Test Method for Determining Floor Flatness and Floor

SECTION 03 30 00 Page 4

Levelness Numbers

ASTM E1643 (2018a) Standard Practice for Selection, Design, Installation, and Inspection of Water Vapor Retarders Used in Contact with Earth or Granular Fill Under Concrete Slabs

ASTM E1745 (2017) Standard Specification for Water Vapor Retarders Used in Contact with Soil or Granular Fill under Concrete Slabs

CONCRETE REINFORCING STEEL INSTITUTE (CRSI)

CRSI 10MSP (2018) Manual of Standard Practice

CRSI RB4.1 (2016) Supports for Reinforcement Used in Concrete

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST)

NIST PS 1 (2009) DOC Voluntary Product Standard PS 1-07, Structural Plywood

U.S. ARMY CORPS OF ENGINEERS (USACE)

COE CRD-C 104 (1980) Method of Calculation of the Fineness Modulus of Aggregate

COE CRD-C 572 (1974) Corps of Engineers Specifications for Polyvinylchloride Waterstops

1.2 DEFINITIONS

a. "Cementitious material" as used herein must include all portland cement, and fly ash.

b. "Exposed to public view" means situated so that it can be seen from eye level from a public location after completion of the building. A public location is accessible to persons not responsible for operation or maintenance of the building.

c. "Chemical admixtures" are materials in the form of powder or fluids that are added to the concrete to give it certain characteristics not obtainable with plain concrete mixes.

d. "Supplementary cementing materials" (SCM) include coal fly ash, when used in such proportions to replace the portland cement that result in improvement to sustainability and durability and reduced cost.

e. "Design strength" (f'c) is the specified compressive strength of concrete at time(s) specified in this section to meet structural design criteria.

f. "Mass Concrete" is any concrete system that approaches a maximum temperature of 158 degrees F within the first 72 hours of placement.

In addition, it includes all concrete elements with a section thickness of 3 feet or more regardless of temperature.

g. "Mixture proportioning" is the process of designing concrete mixture

SECTION 03 30 00 Page 5 proportions to enable it to meet the strength, service life and constructability requirements of the project while minimizing the initial and life-cycle cost.

h. "Mixture proportions" are the masses or volumes of individual ingredients used to make a unit measure (cubic meter or cubic yard) of concrete.

i . "Workability (or consistence)" is the ability of a fresh (plastic) concrete mix to fill the form/mould properly with the desired work (vibration) and without reducing the concrete's quality. Workability depends on water content, chemical admixtures, aggregate (shape and size distribution), cementitious content and age (level of hydration).

1.3 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for information only. When used, a code following the "G" classification identifies the office that will review the submittal for the Government.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-01 Preconstruction Submittals

Concrete Curing Plan

Quality Control Plan ; G

Quality Control Personnel Certifications ; G

Quality Control Organizational Chart

Laboratory Accreditation ; G

Maturity Method Data

Thermal Control Plan (TCP); G

SD-02 Shop Drawings

Reinforcing Steel ; G

SD-03 Product Data

Joint Sealants

Joint Filler

Formwork Materials

Recycled Aggregate Materials

Cementitious Materials

Vapor Retarder

Concrete Curing Materials

SECTION 03 30 00 Page 6

Reinforcement

Liquid Chemical Floor Hardeners and Sealers

Admixtures

Mechanical Reinforcing Bar Connectors

Waterstops

Local/Regional Materials

Biodegradable Form Release Agent

Pumping Concrete

Nonshrink Grout

SD-05 Design Data

Concrete Mix Design ; G

SD-06 Test Reports

Concrete Mix Design ; G

Fly Ash

Aggregates

Tolerance Report

Compressive Strength Tests ; G

Unit Weight of Structural Concrete

Air Content

Slump Tests

Water

SD-07 Certificates

Reinforcing Bars

Field Testing Technician and Testing Agency

SD-08 Manufacturer's Instructions

Liquid Chemical Floor Hardeners and Sealers

Joint Sealants

Curing Compound

1.4 MODIFICATION OF REFERENCES

Accomplish work in accordance with ACI publications except as modified

SECTION 03 30 00 Page 7 herein. Consider the advisory or recommended provisions to be mandatory.

Interpret reference to the "Building Official," the "Structural Engineer," and the "Architect/Engineer" to mean the Contracting Officer.

1.5 DELIVERY, STORAGE, AND HANDLING

Follow ACI 301 , ACI 304R and ASTM A934/A934M requirements and recommendations. Do not deliver concrete until vapor retarder, forms, reinforcement, embedded items, and chamfer strips are in place and ready for concrete placement. Do not store concrete curing compounds or sealers with materials that have a high capacity to adsorb volatile organic compound (VOC) emissions. Do not store concrete curing compounds or sealers in occupied spaces.

1.5.1 Reinforcement

Store reinforcement of different sizes and shapes in separate piles or racks raised above the ground to avoid excessive rusting. Protect from contaminants such as grease, oil, and dirt. Ensure bar sizes can be accurately identified after bundles are broken and tags removed.

1.6 QUALITY ASSURANCE

1.6.1 Design Data

1.6.1.1 Concrete Mix Design

Sixty days minimum prior to concrete placement, submit a mix design for each strength and type of concrete. Submit a complete list of materials including type; brand; source and amount of cement, supplementary cementitious materials, and admixtures; and applicable reference specifications. Submit mill test and all other test for cement, supplementary cementitious materials, aggregates, and admixtures. Provide documentation of maximum nominal aggregate size, gradation analysis, percentage retained and passing sieve, and a graph of percentage retained verses sieve size. Mix proportions must have a maximum water/cement ratio of 0.45. If source material changes, resubmit mix proportion data using revised source material. Provide only materials that have been proven by trial mix studies to meet the requirements of this specification, unless otherwise approved in writing by the Contracting Officer. Indicate clearly in the submittal where each mix design is used when more than one mix design is submitted. Resubmit data on concrete components if the qualities or source of components changes. For previously approved concrete mix designs used within the past twelve months, the previous mix design may be re-submitted without further trial batch testing if accompanied by material test data conducted within the last six months.

Obtain mix design approval from the contracting officer prior to concrete placement.

1.6.2 Shop Drawings

1.6.2.1 Reinforcing Steel

Indicate bending diagrams, assembly diagrams, splicing and laps of bars, shapes, dimensions, and details of bar reinforcing, accessories, and concrete cover. Do not scale dimensions from structural drawings to determine lengths of reinforcing bars. Reproductions of contract drawings are unacceptable.

SECTION 03 30 00 Page 8

1.6.3 Control Submittals

1.6.3.1 Concrete Curing Plan

Submit proposed materials, methods and duration for curing concrete elements in accordance with ACI 308.1 .

1.6.3.2 Pumping Concrete

Submit proposed materials and methods for pumping concrete. Submittal must include mix designs, pumping equipment including type of pump and size and material for pipe, and maximum length and height concrete is to be pumped.

1.6.4 Test Reports

1.6.4.1 Fly Ash

Submit test results in accordance with ASTM C618 for fly ash and pozzolan. Submit test results performed within 6 months of submittal date.

1.6.4.2 Aggregates

Submit test results in accordance with ASTM C33/C33M, or ASTM C330/C330M for lightweight aggregate, and ASTM C1293 or ASTM C1567 as required in the paragraph titled ALKALI-AGGREGATE REACTION.

1.6.5 Quality Control Plan

Develop and submit for approval a concrete quality control program in accordance with the guidelines of ACI 121R and as specified herein. The plan must include approved laboratories. Provide direct oversight for the concrete qualification program inclusive of associated sampling and testing. All quality control reports must be provided to the Contracting Officer, Quality Manager and Concrete Supplier. Maintain a copy of ACI SP-15 and CRSI 10MSP at project site.

1.6.6 Quality Control Personnel Certifications

The Contractor must submit for approval the responsibilities of the various quality control personnel, including the names and qualifications of the individuals in those positions and a quality control organizational chart defining the quality control hierarchy and the responsibility of the various positions. Quality control personnel must be employed by the Contractor.

Submit American Concrete Institute certification for the following:

a. CQC personnel responsible for inspection of concrete operations.

b. Lead Foreman or Journeyman of the Concrete Placing, Finishing, and Curing Crews.

c. Field Testing Technicians: ACI Concrete Field Testing Technician, Grade I.

1.6.6.1 Quality Manager Qualifications

The quality manager must hold a current license as a professional engineer

SECTION 03 30 00 Page 9 in a U.S. state or territory with experience on at least five similar projects. Evidence of extraordinary proven experience may be considered by the Contracting Officer as sufficient to act as the Quality Manager.

1.6.6.2 Field Testing Technician and Testing Agency

Submit data on qualifications of proposed testing agency and technicians for approval by the Contracting Officer prior to performing testing on concrete.

a. Work on concrete under this contract must be performed by an ACI Concrete Field Testing Technician Grade 1 qualified in accordance with ACI SP-2 or equivalent. Equivalent certification programs must include requirements for written and performance examinations as stipulated in ACI SP-2 .

b. Testing agencies that perform testing services on reinforcing steel must meet the requirements of ASTM E329.

c. Testing agencies that perform testing services on concrete materials must meet the requirements of ASTM C1077.

1.6.7 Laboratory Qualifications for Concrete Qualification Testing

The concrete testing laboratory must have the necessary equipment and experience to accomplish required testing. The laboratory must meet the requirements of ASTM C1077 and be Cement and Concrete Reference Laboratory (CCRL) inspected.

1.6.8 Laboratory Accreditation

Laboratory and testing facilities must be provided by and at the expense of the Contractor. The laboratories performing the tests must be accredited in accordance with ASTM C1077, including ASTM C78/C78M and ASTM C1260. The accreditation must be current and must include the required test methods, as specified. Furthermore, the testing must comply with the following requirements:

a. Aggregate Testing and Mix Proportioning: Aggregate testing and mixture proportioning studies must be performed by an accredited laboratory and under the direction of a registered professional engineer in a U.S. state or territory competent in concrete materials who is competent in concrete materials and must sign all reports and designs.

b. Acceptance Testing: Furnish all materials, labor, and facilities required for molding, curing, testing, and protecting test specimens at the site and in the laboratory. Furnish and maintain boxes or other facilities suitable for storing and curing the specimens at the site while in the mold within the temperature range stipulated by

ASTM C31/C31M.

c. Contractor Quality Control: All sampling and testing must be performed by an approved, onsite, independent, accredited laboratory.

1.7 ENVIRONMENTAL REQUIREMENTS

Provide space ventilation according to material manufacturer recommendations, at a minimum, during and following installation of concrete curing compound and sealer. Maintain one of the following

SECTION 03 30 00 Page 10 ventilation conditions during the curing period or for 72 hours after installation:

a. Supply 100 percent outside air 24 hours a day.

b. Supply airflow at a rate of 6 air changes per hour, when outside temperatures are between 55 degrees F and 84 degrees F and humidity is between 30 percent and 60 percent.

c. Supply airflow at a rate of 1.5 air changes per hour, when outside air conditions are not within the range stipulated above.

1.7.1 Submittals for Environmental Performance

a. Provide data indication the percentage of post-industrial pozzolan (fly ash, slag cement) cement substitution as a percentage of the full product composite by weight.

b. Provide data indicating the percentage of post-industrial and post-consumer recycled content aggregate.

c. Provide product data indicating the percentage of post-consumer recycled steel content in each type of steel reinforcement as a percentage of the full product composite by weight.

d. Provide product data stating the location where all products were manufactured

e. For projects using FSC certified formwork, provide chain-of-custody documentation for all certified wood products.

f. For projects using reusable formwork, provide data showing how formwork is reused.

g. Provide SDS product information data showing that form release agents meet any environmental performance goals such as using vegetable and soy based products.

h. Provide SDS product information data showing that concrete adhesives meet any environmental performance goals including low emitting, low volatile organic compound products.

1.8 SUSTAINABLE DESIGN REQUIREMENTS

1.8.1 Local/Regional Materials

Use materials or products extracted, harvested, or recovered, as well as manufactured, within a 500 mile radius from the project site, if available from a minimum of three sources.See Section 01 33 29 SUSTAINABILITY REQUIREMENTS AND REPORTING for cumulative total local material requirements. Concrete materials may be locally available.

1.9 MASS CONCRETE (FOOTINGS 3'-0" THICK AND GREATER)

Submittals for mass concrete must be submitted concurrently. Incomplete submittals will be rejected without review.

a. Thermal Control Plan (TCP); Developed by a qualified engineer registered in the state of Maryland. The TCP must included, at a

SECTION 03 30 00 Page 11 minimum:

1) Proposed concrete mix for footings that are 4 foot thick and greater.

2) Calculated or measured adiabatic temperature rise of concrete.

3) Upper limit for concrete temperature at the time of placement.

4) Description of specific measures and equipment that will be used to ensure maximum temperature in placement will not exceed specified maximum temperature limit.

5) Calculated maximum temperature in placement based on expected conditions at time of placement and use of proposed measure to control temperatures.

6) Description of specific measures and equipment that will be used to ensure temperature difference will not exceed specified temperature difference limit.

7) Calculated maximum temperature difference in placement based on expected conditions at time of placement and use of proposed measures to control temperature difference.

8) Description of equipment and procedures that will be used to monitor and log temperatures and temperature differences.

9) Drawing of locations for temperature sensors in placement.

10) Description of format of providing temperature data (temperature readings must be taken on each hour).

11) Description of measures to address and reduce excessive temperature differences if they occur.

12) Description of curing procedures, including materials and methods, and curing duration and proposed methods to control maximum temperature during curing. A mechanical cooling system may be used to control the internal concrete temperatures of mass concrete during curing. If used, the mechanical cooling system operations and final grouting must be submitted in detail within the TCP.

13) Description of formwork removal procedures to ensure temperature difference at the temporarily exposed surface will not exceed temperature difference limit, and how curing will be maintained.

14) Actions to be taken when the concrete exceed the maximum allowable internal and differential temperatures.

15) Product date of the proposed temperature sensors and date logging equipment.

If the concrete mixture proportions are changed, the thermal control plan must be updated and resubmitted to the Government.

b. Monitoring report: Contractor must submit temperature monitoring records to the Architect daily. A final report must be prepared and

SECTION 03 30 00 Page 12 submitted to the Government with all collected data after the pile cap is cured.

c. All mass concrete must be constructed in accordance with the following procedures:

1) ACI 207.1-05: Guide to Mass Concrete

2) ACI 207.2-07: Report on Thermal and Volume Change Effect on Cracking on Mass Concrete

3) ACI 207.4-05: Cooling and Insulating System for Mass Concrete

4) ACI 301-16: Specifications for Structural Concrete

d. Temperature Sensors:

1) At each location where the concrete temperature is to be monitored, include two independent sets of sensing devices and at locations included in the TCP. One primary sensor and one backup sensor.

2) Sensors must be electronic, accurate to within +2 deg F, and fully capable of measuring temperature ranges of 32 deg. F to 212 deg F.

3) Sensors must be placed at the following locations:

a) Centroid of the mass pour (vertical and horizontal)

b) Nearest surface in a horizontal and vertical line to the centroid. Sensor must be placed at a depth of 2 inches below the surface.

c) On-site ambient air around the mass pour. Place sensor in a shaded location.

4) Temperature readings must be taken once each hour.

e. Cooling system, if used:

1) Fill cooling system lines solid with pumpable, 5,000 psi grout after mass concrete internal temperature has stabilized.

PART 2 PRODUCTS

2.1 FORMWORK MATERIALS

a. Form-facing material in contact with concrete must be lumber, plywood, tempered concrete-form-grade hardboard, metal, plastic, or treated paper that creates specified appearance and texture of concrete surface.

Submit product information on proposed form-facing materials if different from that specified herein.

b. Design formwork, shores, reshores, and backshores to support loads transmitted to them and to comply with applicable building code requirements.

c. Provide temporary openings in formwork if needed to facilitate cleaning and inspection.

SECTION 03 30 00 Page 13

2.1.1 Wood Forms

Provide lumber that is square edged or tongue-and-groove boards, free of raised grain, knotholes, or other surface defects. Provide plywood that complies with NIST PS 1 , B-B concrete form panels or better or AHA A135.4 , hardboard for smooth form lining.

2.1.1.1 Concrete Form Plywood (Standard Rough)

Provide plywood that conforms to NIST PS 1 , B-B, concrete form, not less than 5/8-inch thick.

2.1.1.2 Overlaid Concrete Form Plywood (Standard Smooth)

Provide plywood that conforms to NIST PS 1 , B-B, high density form overlay, not less than 5/8-inch thick.

2.1.2 Steel Forms

Provide steel form surfaces that do not contain irregularities, dents, or sags.

2.2 FORMWORK ACCESSORIES

a. Use commercially manufactured formwork accessories, including ties and hangers.

b. Form ties and accessories must not reduce the effective cover of the reinforcement.

2.2.1 Waterstops

Submit manufacturer's data sheet on waterstop materials and splices.

2.2.1.1 PVC Waterstop

Polyvinylchloride waterstops must conform to COE CRD-C 572 .

2.2.2 Biodegradable Form Release Agent

a. Provide form release agent that is colorless, biodegradable, and water-based .

b. Provide product that does not bond with, stain, or adversely affect concrete surfaces and does not impair subsequent treatments of concrete surfaces.

c. Provide form release agent that reduces formwork moisture absorption, and does not contain diesel fuel, petroleum-based lubricating oils, waxes, or kerosene. Submit documentation indicating type of biobased material in product and biobased content.

d. Submit manufacturer's product data on formwork release agent for use on each form-facing material.

2.2.3 Chamfer Materials

Use lumber materials with dimensions of 3/4 x 3/4 in .

SECTION 03 30 00 Page 14

2.2.4 Construction and movement joints

a. Submit details and locations of construction joints in accordance with the requirements herein.

b. Provide movement joints where indicated in Contract Documents or in accepted alternate locations.

c. Submit location and detail of movement joints if different from those indicated in Contract Documents.

d. Submit manufacturer's data sheet on expansion joint materials.

2.2.5 Other Embedded items

Use sleeves, inserts, anchors, and other embedded items of material and design indicated in Contract Documents.

2.3 CONCRETE MATERIALS

2.3.1 Cementitious Materials

2.3.1.1 Portland Cement

a. Unless otherwise specified, provide cement that conforms to ASTM C150/C150M Type I or II.

b. Use one brand and type of cement for formed concrete having exposed-to-view finished surfaces.

c. Submit information along with evidence demonstrating compliance with referenced standards. Submittals must include types of cementitious materials, manufacturing locations, shipping locations, and certificates showing compliance.

d. Cementitious materials must be stored and kept dry and free from contaminants.

2.3.1.2 Blended Cements

a. Blended cements must conform to ASTM C595/C595M Type IL.

2.3.1.3 Fly Ash

a. ASTM C618, Class F, except that the maximum allowable loss on ignition must not exceed 3 percent.

b. If fly ash is used it shall range from 15 to 20 percent by weight of cementitious material, provided the fly ash does not reduce the amount of cement in the concrete mix below the minimum requirements of local building codes. Where the use of fly ash cannot meet the minimum level,it shall not be used. Report the chemical analysis of the fly ash in accordance with ASTM C311/C311M. Evaluate and classify fly ash in accordance with ASTM D5759.

2.3.2 Water

a. Water or ice must comply with the requirements of ASTM C1602/C1602M .

SECTION 03 30 00 Page 15

b. Minimize the amount of water in the mix. Improve workability by adjusting the grading of the aggregate and using admixture rather than by adding water.

c. Water must be potable; free from injurious amounts of oils, acids, alkalis, salts, organic materials, or other substances deleterious to concrete.

d. Protect mixing water and ice from contamination during storage and delivery.

e. Submit test report showing water complies with ASTM C1602/C1602M .

2.3.3 Aggregate

2.3.3.1 Normal-Weight Aggregate

a. Aggregates must conform to ASTM C33/C33M.

b. Aggregates used in concrete must be obtained from the same sources and have the same size range as aggregates used in concrete represented by submitted field test records or used in trial mixtures.

c. Provide sand that is at least 50 percent acid insoluble based on

ASTM D3042.

d. Store and handle aggregate in a manner that will avoid segregation and prevents contamination by other materials or other sizes of aggregates. Store aggregates in locations that will permit them to drain freely. Do not use aggregates that contain frozen lumps.

e. Submit types, pit or quarry locations, producers' names, aggregate supplier statement of compliance with ASTM C33/C33M, and ASTM C1293 expansion data not more than 18 months old.

2.3.3.2 Recycled Aggregate Materials

Use a minimum of 25 percent recycled aggregate, depending on local availability and conforming to requirements of the mix design. Submit recycled material request with the aggregate certification submittals and do not use until approved by the Contracting Officer.

2.3.4 Admixtures

a. Chemical admixtures must conform to ASTM C494/C494M.

b. Air-entraining admixtures must conform to ASTM C260/C260M.

c. Chemical admixtures for use in producing flowing concrete must conform to ASTM C1017/C1017M .

d. Do not use calcium chloride admixtures.

e. Admixtures used in concrete must be the same as those used in the concrete represented by submitted field test records or used in trial mixtures.

f . Protect stored admixtures against contamination, evaporation, or

SECTION 03 30 00 Page 16 damage.

g. To ensure uniform distribution of constituents, provide agitating equipment for admixtures used in the form of suspensions or unstable solutions. Protect liquid admixtures from freezing and from temperature changes that would adversely affect their characteristics.

h. Submit types, brand names, producers' names, manufacturer's technical data sheets, and certificates showing compliance with standards required herein.

2.4 MISCELLANEOUS MATERIALS

2.4.1 Concrete Curing Materials

Provide concrete curing material in accordance with ACI 301 Section 5 and ACI 308.1 Section 2. Submit product data for concrete curing compound s.

Submit manufactures instructions for placement of curing compound. Curing compound must conform to ASTM C309, white pigmented, Type 2, Class B, free of petroleum.

2.4.2 Nonshrink Grout

Nonshrink grout in accordance with ASTM C1107/C1107M .

2.4.3 Floor Finish Materials

2.4.3.1 Liquid Chemical Floor Hardeners and Sealers

a. Hardener must be a colorless aqueous solution containing a blend of inorganic silicate or siliconate material and proprietary components combined with a wetting agent; that penetrates, hardens, and densifies concrete surfaces. Submit manufactures instructions for placement of liquid chemical floor hardener.

b. Use concrete penetrating sealers with a low (maximum 100 grams/liter, less water and less exempt compounds) VOC content. Submit manufactures instructions for placement of sealers.

2.4.4 Expansion/Contraction Joint Filler

ASTM D1751 or ASTM D1752 Type I or Type II. Material must be 1/2 inch thick, unless otherwise indicated.

2.4.5 Joint Sealants

2.4.5.1 Horizontal Surfaces, 3 Percent Slope, Maximum

ASTM D6690 or ASTM C920, Type M, Class 25, Use T.

2.4.5.2 Vertical Surfaces Greater Than 3 Percent Slope

ASTM C920, Type M, Grade NS, Class 25, Use T.

2.4.5.3 Preformed Polychloroprene Elastomeric Type

ASTM D2628.

SECTION 03 30 00 Page 17

2.4.6 Vapor Retarder

ASTM E1745 Class C polyethylene sheeting, minimum 15 mil thickness or other equivalent material with a maximum permeance rating of 0.04 perms per ASTM E96/E96M.

2.5 CONCRETE MIX DESIGN

2.5.1 Properties and Requirements

a. Use materials and material combinations listed in this section and the contract documents.

b. Cementitious material content must be adequate for concrete to satisfy the specified requirements for strength, w/cm, durability, and finishability described in this section and the contract documents.

c. Selected target slump must meet the requirements this section, the contract documents, and must not exceed values indicated in the table below . Concrete must not show visible signs of segregation.

d. The target slump must be enforced for the duration of the project.

Determine the slump by ASTM C143/C143M. Slump tolerances must meet the requirements of ACI 117 .

e. The nominal maximum size of coarse aggregate for a mixture must not exceed three-fourths of the minimum clear spacing between reinforcement, one-fifth of the narrowest dimension between sides of forms, or one-third of the thickness of slabs or toppings.

f. Concrete must be air entrained for members assigned to Exposure Class F1, F2, or F3. The total air content must be in accordance with the requirements of the paragraph titled DURABILITY.

g. Measure air content at the point of delivery in accordance with ASTM C173/C173M or ASTM C231/C231M.

h. Concrete for slabs to receive a hard-troweled finish must not contain an air-entraining admixture or have a total air content greater than 3 percent.

i. Concrete properties and requirements for each portion of the structure are specified in the table below. Refer to the paragraph titled DURABILITY for more details on exposure categories and their requirements.

Minimum f'c psi Exposure Categories^

Miscellaneous Requirements

Footings and CMU stem walls

4,000 at 28 days

S0, C0, W0, F0

Max. slump: 5 in.

Nominal maxaggregate size :

1 in.

Air content: <3% Maximum water/cement ratio: 0.45

SECTION 03 30 00 Page 18

Minimum f'c psi Exposure Categories^

Miscellaneous Requirements

Slabs-on-ground (Except hangar floor slab)

4,000 at 28 days

S0, C0, W0, F0

Max. slump: 5 in .

Nominal aggregate size : 1 in.

Air content: <3% Maximum water/cement ratio: 0.45

Hangar Bay Floor Slab (Including Front Hangar Door Rail Foundation and Secondary Pour)

6,000 at 28 days

Minimum Flexural Strength: 650 psi at 28 days

S0, C1, W0, F0

Max. slump: 6 in.

Nominal aggregate size: 1 in.

Air content: <3% Maximum water/content ratio: 0.45

Exterior concrete (Mechanical yard floor slab and housekeeping pads)

4,500 at 28 days

S0, C1, W1, F2

Max. slump 5 in.

Nominal aggregate size: 1 in.

Air content: 6% Maximum water/cement ratio: 0.45

2.5.2 Durability

2.5.2.1 Alkali-Aggregate Reaction

Do not use any aggregate susceptible to alkali-carbonate reaction (ACR).

Use one of the three options below for qualifying concrete mixtures to reduce the potential of alkali-silica reaction (ASR):

a. For each aggregate used in concrete, the expansion result determined in accordance with ASTM C1293 must not exceed 0.04 percent at one year.

b. For each aggregate used in concrete, the expansion result of the aggregate and cementitious materials combination determined in accordance with ASTM C1567 must not exceed 0.10 percent at an age of 16 days.

c. Alkali content in concrete (LBA) must not exceed 4 pounds per cubic yard for moderately reactive aggregate or 3 pounds per cubic yard for highly reactive aggregate. Reactivity must be determined by testing in accordance with ASTM C1293 and categorized in accordance with ASTM C1778. Alkali content is calculated as follows:

LBA = (cement content, pounds per cubic yard ) × (equivalent alkali content of portland cement in percent/100 percent)

SECTION 03 30 00 Page 19

2.5.2.2 Concrete Temperature

The temperature of concrete as delivered must not exceed 95°F .

2.5.3 Trial Mixtures

Trial mixtures must be in accordance to ACI 301 .

2.5.4 Ready-Mix Concrete

Provide concrete that meets the requirements of ASTM C94/C94M.

Ready-mixed concrete manufacturer must provide duplicate delivery tickets with each load of concrete delivered. Provide delivery tickets with the following information in addition to that required by ASTM C94/C94M:

a. Type and brand cement

b. Cement and supplementary cementitious materials content in 94-pound bags per cubic yard of concrete

c. Maximum size of aggregate

d. Amount and brand name of admixtures

e. Total water content expressed by water cementitious material ratio

2.6 REINFORCEMENT

a. Bend reinforcement cold. Fabricate reinforcement in accordance with fabricating tolerances of ACI 117 .

b. When handling and storing coated reinforcement, use equipment and methods that do not damage the coating. If stored outdoors for more than 2 months, cover coated reinforcement with opaque protective material.

c. Submit manufacturer's certified test report for reinforcement.

d. Submit placing drawings showing fabrication dimensions and placement locations of reinforcement and reinforcement supports. Placing drawings must indicate locations of splices, lengths of lap splices, and details of mechanical and welded splices.

e. Submit request with locations and details of splices not indicated in Contract Documents.

f. Submit request to place column dowels without using templates.

g. Submit request for field cutting, including location and type of bar to be cut and reason field cutting is required.

2.6.1 Reinforcing Bars

a. Reinforcing bars must be deformed, except spirals, load-transfer dowels, and welded wire reinforcement, which may be plain.

b. ASTM A615/A615M with the bars marked S, Grade 60 . Cold drawn wire

SECTION 03 30 00 Page 20 used for spiral reinforcement must conform to ASTM A1064/A1064M .

c. Submit mill certificates for reinforcing bars.

2.6.1.1 Bar Mats

a. Bar mats must conform to ASTM A184/A184M .

b. If coated bar mats are required, repair damaged coating as required in the paragraph titled EPOXY-COATED REINFORCING BARS.

2.6.2 Mechanical Reinforcing Bar Connectors

a. Provide 125 percent minimum yield strength of the reinforcement bar.

b. Mechanical splices for galvanized reinforcing bars must be galvanized or coated with dielectric material.

c. Mechanical splices used with epoxy-coated or dual-coated reinforcing bars must be coated with dielectric material.

d. Submit data on mechanical splices demonstrating compliance with this paragraph.

2.6.3 Wire

a. Provide wire reinforcement that contains a minimum of 100 percent recycled content. Provide flat sheets of welded wire reinforcement for slabs and toppings.

b. Plain or deformed steel wire must conform to ASTM A1064/A1064M .

c. Epoxy-coated wire must conform to ASTM A884/A884M . Coating damage incurred during shipment, storage, handling, and placing of epoxy-coated wires must be repaired. Repair damaged coating areas with patching material in accordance with material manufacturer's written recommendations. If damaged area exceeds 2 percent of surface area in each linear foot of each wire, wire must not be used. The 2 percent limit on damaged coating area must include repaired areas damaged before shipment as required by ASTM A884/A884M . Fading of coating color shall not be cause for rejection of epoxy-coated wire reinforcement.

2.6.4 Welded wire reinforcement

a. Use welded wire reinforcement specified in Contract Documents and conforming to one or more of the specifications given herein.

b. Plain welded wire reinforcement must conform to ASTM A1064/A1064M .

c. Deformed welded wire reinforcement must conform to ASTM A1064/A1064M , with welded intersections spaced no greater than 16 in. apart in direction of principal reinforcement.

d. Epoxy-coated welded wire reinforcement must conform to ASTM A884/A884M .

Coating damage incurred during shipment, storage, handling, and placing of epoxy-coated welded wire reinforcement must be repaired in accordance with ASTM A884/A884M . Repair damaged coating areas with patching material in accordance with material manufacturer's written

SECTION 03 30 00 Page 21 recommendations. If damaged area exceeds 2 percent of surface area in each linear foot of each wire or welded wire reinforcement, the sheet containing the damaged area must not be used. The 2 percent limit on damaged coating area must include repaired areas damaged before shipment as required by ASTM A884/A884M . Fading of coating color shall not be cause for rejection of epoxy-coated welded wire reinforcement.

2.6.5 Reinforcing Bar Supports

a. Provide reinforcement support types within structure as required by Contract Documents. Reinforcement supports must conform to CRSI RB4.1 .

Submit description of reinforcement supports and materials for fastening coated reinforcement if not in conformance with CRSI RB4.1 .

b. Legs of supports in contact with formwork must be hot-dip galvanized, or plastic coated after fabrication, or stainless-steel bar supports.

2.6.6 Dowels for Load Transfer in Floors

Provide greased dowels for load transfer in floors of the type, design, weight, and dimensions indicated. Provide dowel bars that are plain-billet steel conforming to ASTM A615/A615M , Grade 40. Provide dowel pipe that is steel conforming to ASTM A53/A53M.

2.6.7 Welding

Welding of reinforcement bars is not allowed.

PART 3 EXECUTION

3.1 EXAMINATION

a. Do not begin installation until substrates have been properly constructed; verify that substrates are level.

b. If substrate preparation is the responsibility of another installer, notify Contracting Officer of unsatisfactory preparation before processing.

c. Check field dimensions before beginning installation. If dimensions vary too much from design dimensions for proper installation, notify Contracting Officer and wait for instructions before beginning installation.

3.2 PREPARATION

Determine quantity of concrete needed and minimize the production of excess concrete. Designate locations or uses for potential excess concrete before the concrete is poured.

3.2.1 General

a. Surfaces against which concrete is to be placed must be free of debris, loose material, standing water, snow, ice, and other deleterious substances before start of concrete placing.

b. Remove standing water without washing over freshly deposited concrete.

Divert flow of water through side drains provided for such purpose.

SECTION 03 30 00 Page 22

3.2.2 Subgrade Under Foundations and Footings

a. When subgrade material is semi-porous and dry, sprinkle subgrade surface with water as required to eliminate suction at the time concrete is deposited, or seal subgrade surface by covering surface with specified vapor retarder.

b. When subgrade material is porous, seal subgrade surface by covering surface with specified vapor retarder.

3.2.3 Subgrade Under Slabs on Ground

a. Before construction of slabs on ground, have underground work on pipes and conduits completed and approved.

b. Previously constructed subgrade or fill must be cleaned of foreign materials

c. Finish surface of capillary water barrier under interior slabs on ground must not show deviation in excess of 1/4 inch when tested with a 10-foot straightedge parallel with and at right angles to building lines.

d. Finished surface of subgrade or fill under exterior slabs on ground must not be more than 0.02-foot above or 0.10-foot below elevation indicated.

3.2.4 Edge Forms and Screed Strips for Slabs

a. Set edge forms or bulkheads and intermediate screed strips for slabs to obtain indicated elevations and contours in finished slab surface and must be strong enough to support vibrating bridge screeds or roller pipe screeds if nature of specified slab finish requires use of such equipment.

b. Align concrete surface to elevation of screed strips by use of strike-off templates or approved compacting-type screeds.

3.2.5 Reinforcement and Other Embedded Items

a. Secure reinforcement, joint materials, and other embedded materials in position, inspected, and approved before start of concrete placing.

b. When concrete is placed, reinforcement must be free of materials deleterious to bond. Reinforcement with rust, mill scale, or a combination of both will be considered satisfactory, provided minimum nominal dimensions, nominal weight, and minimum average height of deformations of a hand-wire-brushed test specimen are not less than applicable ASTM specification requirements.

3.3 FORMS

a. Provide forms, shoring, and scaffolding for concrete placement. Set forms mortar-tight and true to line and grade.

b. Chamfer above grade exposed joints, edges, and external corners of concrete 0.75 inch . Place chamfer strips in corners of formwork to produce beveled edges on permanently exposed surfaces.

SECTION 03 30 00 Page 23

c. Provide formwork with clean-out openings to permit inspection and removal of debris.

d. Inspect formwork and remove foreign material before concrete is placed.

e. At construction joints, lap form-facing materials over the concrete of previous placement. Ensure formwork is placed against hardened concrete so offsets at construction joints conform to specified tolerances.

f . Construct formwork for openings to facilitate removal and to produce opening dimensions as specified and within tolerances.

g. Position and support expansion joint materials, waterstops, and other embedded items to prevent displacement.

h. Clean surfaces of formwork and embedded materials of mortar, grout, and foreign materials before concrete placement.

3.3.1 Coating

a. Cover formwork surfaces with an acceptable material that inhibits bond with concrete.

b. If formwork release agent is used, apply to formwork surfaces in accordance with manufacturer's recommendations before placing reinforcement. Remove excess release agent on formwork prior to concrete placement.

c. Do not allow formwork release agent to contact reinforcement or hardened concrete against which fresh concrete is to be placed.

3.3.2 Reuse

a. Reuse forms providing the structural integrity of concrete and the aesthetics of exposed concrete are not compromised.

b. Wood forms must not be clogged with paste and must be capable of absorbing high water-cementitious material ratio paste.

c. Remove leaked mortar from formwork joints before reuse.

3.3.3 Forms for Standard Rough Form Finish

Provide formwork in accordance with ACI 301 Section 5 with a surface finish, SF-1.0, for formed surfaces that are to be concealed by other construction.

3.3.4 Forms for Standard Smooth Form Finish

Provide formwork in accordance with ACI 301 Section 5 with a surface finish, SF-3.0, for formed surfaces that are exposed to view.

3.3.5 Form Ties

a. For post-tensioned structures, do not remove formwork supports until stressing records have been accepted by the Contracting Officer.

SECTION 03 30 00 Page 24

b. After ends or end fasteners of form ties have been removed, repair tie holes in accordance with ACI 301 Section 5 requirements.

3.3.6 Forms for Concrete Pan Joist Construction

Pan-form units for one-way or two-way concrete joist and slab construction must be factory-fabricated units of the approximate section indicated.

Units must consist of steel or molded fiberglass concrete form pans.

Closure units must be furnished as required.

3.3.7 Removal of Forms and Supports

a. If vertical formed surfaces require finishing, remove forms as soon as removal operations will not damage concrete.

b. Remove top forms on sloping surfaces of concrete as soon as removal will not allow concrete to sag. Perform repairs and finishing operations required. If forms are removed before end of specified curing period, provide curing and protection.

c. Do not damage concrete during removal of vertical formwork for columns, walls, and sides of beams. Perform needed repair and finishing operations required on vertical surfaces. If forms are removed before end of specified curing period, provide curing and protection.

d. Form-facing material and horizontal facing support members may be removed before in-place concrete reaches specified compressive strength if shores and other supports are designed to allow facing removal without deflection of supported slab or member.

3.3.8 Strength of Concrete Required for Removal of Formwork

If removal of formwork, reshoring, or backshoring is based on concrete reaching a specified in-place strength, mold and field-cure cylinders in accordance with ASTM C31/C31M. Test cylinders in accordance with ASTM C39/C39M. Alternatively, use one or more of the methods listed herein to evaluate in-place concrete strength for formwork removal.

a. Tests of cast-in-place cylinders in accordance with ASTM C873/C873M.

This option is limited to slabs with concrete depths from 5 to 12 in .

b. Penetration resistance in accordance with ASTM C803/C803M.

c. Pullout strength in accordance with ASTM C900.

d. Maturity method in accordance with ASTM C1074. Submit maturity method data using project materials and concrete mix proportions used on the project to demonstrate the correlation between maturity and compressive strength of laboratory cured test specimens to the Contracting Officer.

3.4 WATERSTOP INSTALLATION AND SPLICES

a. Provide waterstops in construction joints as indicated.

b. Install formwork to accommodate waterstop materials. Locate waterstops in joints where indicated in Contract Documents. Minimize number of splices in waterstop. Splice waterstops in accordance with

SECTION 03 30 00 Page 25 manufacturer's written instructions. Install factory-manufactured premolded mitered corners.

c. Install waterstops to form a continuous diaphragm in each joint. Make adequate provisions to support and protect waterstops during progress of work.